Systems and methods for cold spray additive manufacturing and repair with gas recovery

ABSTRACT

Implementations provide cold spray additive manufacturing (“CSAM”) with gas recovery in situ in an open environment without requiring part disassembly and removal to a repair facility. Recapturing and reusing gas in an open environment reduces costs, rendering CSAM more commercially viable and efficient, and avoids risk of new damage to parts from contemporary pre-existing CSAM processes. A gas recovery nozzle attaches to a supersonic nozzle and sends used gas to a gas recovery sub-system by capturing gas that is deflected on impact with the part during CSAM. Captured gas is stored for reuse. A flexible coupling controls distance from the gas recovery nozzle to a part substrate to prevent (1) nozzle clogging; (2) stationary shock wave interference with gas flow; and (3) gas flow misdirection. The gas recovery nozzle also suppresses disruptive supersonic sounds. Implementations enable capture for later reuse of supersonically-propelled gas during in-situ CSAM in open environments.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 62/867,221, filed on Jun. 26, 2019 andentitled “SYSTEMS AND METHODS FOR COLD SPRAY ADDITIVE MANUFACTURING ANDREPAIR WITH GAS RECOVERY”, which is incorporated by reference herein inits entirety.

BACKGROUND

Commercially viable and efficient cold spray additive manufacturing(“CSAM”) to repair vehicles and other items requires the use of asupersonically propelled gas. For certain commercial applications,Helium is particularly effective. Helium supply is finite; Helium is anexpensive resource that has been increasing in cost over time. As aresult of the increasing acquisition cost of Helium, commercially viableand efficient CSAM deployment becomes increasingly less viable. Withoutthe ability to reuse Helium from one CSAM repair session to the next,the acquisition cost of fresh Helium typically represents the bulk oftotal repair costs.

Without remediation, when spraying without a gas recovery booth gas usedin CSAM is lost after a single use. Further, in some cases, the gasflies close to the substrate of the part that is subject to CSAM and isthus even more difficult to recover. Thus, in contemporary pre-existingcold spray implementations, cold spraying in an open environment (e.g.,an airplane repair hangar) is completely non-viable, being too complexand expensive. And, no open environment cold spray gas recovery systemexists.

Currently available CSAM-based part repair solutions use cold spray in abooth incorporating a gas recovery system to recapture the used gas forpurification and reuse. This limits the applicability of cold spray todisassembled components that fit within the booth. Booth-based solutionshave limited technological impact and restricted commercial application.Damaged parts must be disassembled, shipped to a repair facility,repaired in a booth, shipped back to the point of origin, andreassembled. The booth-based process is inefficient, expensive, andintroduces multiple vectors for new damage to parts, requiring furthercostly repair or replacement. Current supersonic CSAM is also loud,causing disruption and often requiring hearing protection when inoperation.

SUMMARY

Some implementations provide a gas recovery nozzle. The gas recoverynozzle includes a main body configured to attach to a supersonic nozzle.A first end has angled walls at an opening defining a gas flow path fromthe supersonic nozzle. A passage extends from the first end to a secondend, the first end being a distal end and the second end being aproximal end relative to the supersonic nozzle. A cavity surrounds thepassage and is configured to collect at least some gas expelled from thesupersonic nozzle. The cavity defines a gas recovery path. An outletwithin the main body is configured to connect to a gas recoverysub-system.

Other implementations provide a method for performing cold sprayadditive manufacturing. The method includes propelling particles to asubstrate through a nozzle at a supersonic speed using a gas to performcold spray additive manufacturing of a part, capturing a flow of the gaspropelled from an end of the nozzle, and circulating the flow of the gasto a gas recovery system.

Still other implementations provide a system for performing cold sprayadditive manufacturing with gas recovery. The system includes a roboticcontrol system configured to control a cold spray apparatus. The coldspray apparatus has a supersonic nozzle and is configured to performcold spray additive manufacturing of a part. The system further includesa gas recovery nozzle comprising: a main body configured to attach tothe supersonic nozzle, a first end having angled walls at an openingdefining a gas flow path from the supersonic nozzle; a passage extendingfrom the first end to a second end, the first end being a distal end andthe second end being a proximal end relative to the supersonic nozzle, acavity surrounding the passage and configured to collect at least somegas expelled from the supersonic nozzle and defining a gas recoverypath, and an outlet within the main body configured to connect to a gasrecovery sub-system. The gas recovery sub-system is configured toconnect to the outlet and also configured to collect at least some gasexpelled from the supersonic nozzle through the gas recovery path into astorage device. At least some gas collected into the storage device isstored for treatment and reuse in the cold spray apparatus.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. The foregoing Summary, as well as the following DetailedDescription of certain implementations, will be better understood whenread in conjunction with the appended drawings. This Summary is notintended to identify key features or essential features of the claimedsubject matter, nor is it intended to be used as an aid in determiningthe scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings,wherein:

FIG. 1 is a cross-sectional side elevation illustration of animplementation of a gas recovery nozzle in accordance with animplementation.

FIG. 2 is a side elevation illustration of a spray path of animplementation of a cold spray additive manufacturing and repair systemin accordance with an implementation.

FIG. 3 is a flowchart illustrating a method for performing cold sprayadditive manufacturing of a part in accordance with an implementation.

FIG. 4 is a flowchart illustrating another method for performing coldspray additive manufacturing of a part in accordance with animplementation.

FIG. 5 is a block diagram illustrating an operating environment showingan implementation of a system for performing cold spray additivemanufacturing with gas recovery in accordance with an implementation.

FIG. 6 is a flow chart illustrating a method for aircraft manufacturingand service in accordance with an implementation.

FIG. 7 is a schematic perspective view of an aircraft in accordance withan implementation.

FIG. 8 is a functional block diagram illustrating a computing apparatusin accordance with an implementation.

Corresponding reference characters indicate corresponding partsthroughout the drawings in accordance with an implementation.

DETAILED DESCRIPTION

Cold spray additive manufacturing (also “cold spray” or “CSAM” herein)is a material-deposition process where metal or metal-ceramic mixturesof powders (also referred to as “particles” herein) suspended in a gaspropelled at supersonic speed are used to form a coating or freestandingstructure. Specifically, cold spraying is defined herein as spraying amaterial at a temperature that is below the melting point of thematerial being sprayed. CSAM is a solid state process: neither thepowders nor the substrate to which the powders are applied are meltedduring the process. Thus, use of CSAM provides material-deposition thatdoes not cause thermally induced alterations to the substrate or powder(e.g., deformation, crystallization, imperfections, or other types ofdamage). Due to the direct impingement of the gases carrying the powdersupon the substrate, cold spray generates a stationary shock wave andalso a lateral flow of gas along the surface of the part subject toCSAM.

As used herein, a stationary shock wave in the context of the flow ofsupersonic gas (also called a “stationary normal shock wave”) is adiscontinuity that forms in order for the flow to meet some downstreamcondition (e.g., an obstacle or back pressure). When the back pressurebecomes too great, the flow of gas cannot achieve supersonic speeds andis compressed at the nozzle before expanding. The presence of stationaryshock waves thus detracts from optimal supersonic gas flow in CSAMsystems and methods. Implementations of the disclosure also mitigatesuch stationary shock waves.

High- and low-pressure cold spray is an emerging technology findingincreasing applications in various types of structural repairs. In someimplementations, cold spray is usable to repair metallic structures(e.g., airplane or helicopter components). A closer examination of animplantation of a CSAM apparatus and process is provided in thediscussion of FIG. 5 herein.

Referring to the figures, implementations of the disclosure includesystems and methods for cold spray additive manufacturing with gasrecovery that provide a superior cost/benefit ratio in comparison toconventional cold spray implementations. Recapturing and reusing the gasenables potentially large cost savings and renders cold spray additivemanufacturing far more commercially viable and efficient. The variousimplementations not only allow for the reuse of the gas, but also enablecold spray additive manufacturing to occur in situ in an openenvironment (e.g., repairs on an airplane in an airplane hangar).Because no cold spray booth is required, the implementations completelyavoid the need for disassembly, shipping a damaged part to a repairfacility, conducting repairs in a booth fitted with a gas recoverysystem, shipping back to the point of origin, and reassembly.Comparatively, conducting cold spray additive manufacturing-basedrepairs in situ in an open environment is efficient, far less expensive,and avoids entirely multiple vectors for new damage to parts involved incontemporary pre-existing cold spray processes as well as the associatedfollow-up costly repairs or replacements.

The elements described herein in various implementations operate in anunconventional manner to provide systems and methods for cold sprayadditive manufacturing with gas recovery by utilizing a gas recoverynozzle. Implementations of the gas recovery nozzle are configured toattach to a supersonic nozzle used to conduct cold spray additivemanufacturing. The gas recovery nozzle captures a lateral flow of gasfrom a part under repair and circulates the gas to a gas recoverysub-system. The gas recovery nozzle accomplishes this by creating anenvelope over the supersonic nozzle that captures at least some of thegas that is deflected laterally on impact with the part under repairduring cold spray additive manufacturing. The captured gas is circulatedto the gas recovery sub-system. The gas recovery sub-system collects thecaptured gas into storage devices for later treatment (e.g.,purification) and reuse in future cold spray additive manufacturingprocesses.

Some implementations of the gas recovery nozzle further comprise aflexible coupling to control the standout distance from the gas recoverynozzle to the substrate of the part. Maintaining an efficient standoutdistance between the gas recovery nozzle and the substrate of the part:(1) prevents additive particles from clogging either the supersonicnozzle or the gas recovery nozzle, allowing for a higher sustained rateof gas recovery per unit time; (2) prevents a stationary shock wave ofthe gas recovery nozzle from interfering with a supersonic flow of gas;(3) focuses or redirects the supersonic flow of gas in a useful andbeneficial way; and (4) provides an adequate sealing that increases thegas capture rate. Effects of various standout distances on variousimplementations of the disclosure are discussed elsewhere herein.Further, the gas recovery nozzle acts as a suppressor for the supersonicnozzle, significantly reducing the very high decibel noise, and theassociated disruption (e.g., from hearing damage or an inability to hearshouted warnings in a work area), typical of cold spray additivemanufacturing solutions. In some implementations, the flexible couplingis a single component; in other implementations the flexible coupling isa mechanism with more than one component. Multi-part flexible couplingsinclude but are not limited to flexible couplings assembled using petaljoins.

The implementations of the present disclosure are thus superior totypical implementations of cold spray additive manufacturing systems andmethods that fail completely to capture and reuse gas when repairs areconducted in situ without disassembly and use of a repair booth. Theperformance of implementations of the systems and methods for cold sprayadditive manufacturing with gas recovery disclosed herein, as measuredby the ability to capture and reuse supersonically-propelled gaspropelling particles onto a substrate, substantially equals andsometimes exceeds conventional existing contemporary systems and methodsfor cold spray additive manufacturing with gas recovery having designsthat introduce inherent and unavoidable loss of supersonically-propelledgas.

The disclosure is thus mechanically more robust and more cost effectiveto implement, while at the same time being more effective thanconventional systems and methods for cold spray additive manufacturingat both enabling reuse of supersonically-propelled gas and in-siturepairs.

Referring again to FIG. 1 , a cross-sectional side elevation viewillustrates an implementation of a gas recovery nozzle 100 in accordancewith an implementation. The gas recovery nozzle 100 comprises a mainbody 102 configured to attach to a supersonic nozzle 180 and a first end104 having angled walls 106 at an opening 108 defining a gas flow path110 from the supersonic nozzle 180. In some implementations, a largerdiameter opening is thereby defined at the distal end by an angled wallportion between laterally or longitudinally (e.g., straight) extendingwall portions extending outward from a distal end of the supersonicnozzle. The first end 104 can take different shapes and configurations,such as having curved or arcuate walls that are continuously orgradually increasing or decreasing in curvature. That is, the presentdisclosure contemplates different conical shaped ends, or ends havingdifferent angled openings.

It should be noted that the first end 104 is illustrated as beinglocated within the main body 102. However, the first end 104 in someimplementations extends to the end of the main body 102. In variousimplementations the first end 104 is co-axial with the main body 102.

The gas recovery nozzle 100 further comprises a passage 112 extendingfrom the first end 104 to a second end 114. The first end 104 is adistal end and the second end 114 is a proximal end relative to thesupersonic nozzle 180. The gas recovery nozzle 100 further comprises acavity 116 surrounding the passage 112. The cavity 116 is configured tocollect at least some gas 160 expelled from the supersonic nozzle 180.In some implementations, an open end 140 of the cavity 116 at a partside 142 comprises curved walls 144 (e.g., arcuate shaped). In someother implementations, the open end 140 of the cavity 116 extendsfarther distally than the opening 108 at the first end 104 (and has agreater diameter than the first end 104 such that a space is definedbetween a gas flow path having the opening 108, and an inner surface ofthe main body 102). That is, the conical shaped first end 104 ispositioned concentrically within the main body 102 and does not extendto the open end 140. The curved wall 144 is shaped and/or configured tofacilitate capture of the expelled gas 160 after impinging on a part152.

In some implementations, the gas 160 comprises an at least one of Heliumor Nitrogen gas. In some implementations including the supersonic nozzle180, Helium is the preferred gas 160. In the supersonic nozzle 180, thespeed of the gas 160 correlates with the speed of sound and the Machnumber of the gas 160. For Helium, the speed of sound at standardatmospheric conditions is 1007 m/s (1620 k/s). For Nitrogen, the speedof sound at standard atmospheric conditions is only 349 m/s (561 k/s).This translates into higher particle velocities when Helium is usedversus when Nitrogen is used. Thus, if cost and availability are notdeciding factors (that is, if the disclosure herein is implemented suchthat the gas 160 is reusable across cold spray sessions), then Heliumprovides superior performance in CSAM applications versus Nitrogen.

The cavity 116 defines a gas recovery path 162 that leads to an outlet118. That is, the gas recovery nozzle 100 further comprises the outlet118 within the main body 102 configured to connect to a gas recoverysub-system 190. In some implementations, the outlet 118 comprises anopening 120 configured to connect to a compressor pump 192 of the gasrecovery sub-system 190. In some implementations including thecompressor pump 192, a gas diffuser 196 is provided at the opening 120of the cavity 116, which can be located inside, outside, or both insideand outside the cavity 116. The gas diffuser is constructed of an openpore metallic foam (e.g., ALUPOR™ cast aluminum metallic foam) or anymechanically equivalent material or component (e.g., a RADNOR® 14 Seriesgas diffuser). The gas diffuser 196 is configured to slow the flow ofthe gas 160 inside the cavity 116 to the opening 120. The gas diffuser196 facilitates at least one of slowing the flow of gas 160 or directingthe flow of gas 160 to the compressor pump 192.

Other implementations replace or complement the compressor pump 192 withanother suitable type of pump, a turbofan, or any other mechanicallysuitable mechanism configured to pull the gas 160 into the gas recoverysub-system 190. In some other implementations, the outlet 118 comprisesan opening 120 configured to connect to a movable gas recovery tank 194.In some implementations, more than one moveable gas recovery tank 194 isconnected to the opening 120. In implementations including the moveablegas recovery tank 194, the compressor pump 192, other suitable type ofpump, the turbofan, vacuum, or any other mechanically suitable mechanismconfigured to both intake the gas 160 into the gas recovery sub-system190 is further configured to ensure that the greatest possible volume ofthe gas 160 is compressed into and stored in the moveable gas recoverytank 194. Once the gas 160 is stored, the gas 160 is available forpurification and reuse with suitable processes and apparatuses asdescribed elsewhere herein (see, e.g., the discussion of FIG. 5 ). Insome implementations, purification includes removal of Oxygen and othermatter that is not the gas 160.

In some implementations, the main body 102 is tubular and configured tosurround an end 182 of the supersonic nozzle 180. In some otherimplementations, the main body 102 is configured as a removable cover130 to capture a flow of gas 160 from the supersonic nozzle 180 andcirculate the gas 160 to the gas recovery sub-system 190. That is, themain body 102 is removably coupled to the supersonic nozzle 180, whichmay include mechanical attachment (e.g., bolt or screw attachment to aportion of the base of the supersonic nozzle 180) to secure the mainbody 102 thereto. That is, in some implementations, the gas recoverynozzle 100 is fixed proximate to the supersonic nozzle 180 by at leastone screw or other mechanically suitable fastener.

Some implementations of the gas recovery nozzle 100 further comprise aflexible coupling 150 attached to the first end 104 and configured toengage the part 152. The part 152 is any item (e.g., portion of anaircraft or helicopter) requiring CSAM repair processes. In someimplementations, the flexible coupling 150 is ring-shaped and positionedproximate to the substrate of the part 152 and forms at least a partialseal between the gas recovery nozzle 100 and the part 152. When formingat least a partial seal, the flexible coupling 150 comprises a gascapture cover 154. The flexible coupling 150 is constructed of at leastone of an elastomer, flexible metallic material, or other mechanicallysuitable material that is sufficiently durable to provide an acceptableservice lifetime before needing replacement, and also able to conform tothe contours and dimensions of variously shaped parts 152. The flexiblecoupling 150, which is configured as a gas capture cover 154 in theillustrated implementation, addresses the standout distance effect,which has considerable performance implications for any implementationof CSAM in general and the gas recovery nozzle 100 in particular. If thestandout distance between the gas recovery nozzle 100 and the part 152is too small, the gas recovery nozzle 100 will be subject to cloggingand other phenomenon having a deleterious performance impact andeventually requiring cleaning or even replacement. If the standoutdistance between the gas recovery nozzle 100 and the part 152 is toogreat, the performance of the gas recovery nozzle 100 degrades, leadingto the escape of some or even all of the gas 160 otherwise subject tocapture by the gas recovery nozzle 100. The flexible coupling 150addresses the standout distance effect by (1) providing superior controlof the exact standout distance during any CSAM repair session versusimplementations not using the flexible coupling 150, and (2) in someimplementations, directly contacting or almost contacting the substrateof the part 152 to further reduce the amount of used gas able to escaperecapture. In some implementations, the flexible coupling 150 furthercomprises a spring or mechanical or electrical actuator to maintain suchcontact or partial contact. In some implementations, the flexiblecoupling 150 is a single component; in other implementations theflexible coupling 150 is a mechanism with more than one component.Multi-part flexible couplings 150 include but are not limited toflexible couplings 150 assembled using petal joins.

Modelling and experiments using implementations of the presentdisclosure indicate that negligible or zero gas recovery occurs when thestandout distance is greater than or equal to one millimeter. Varioussuch models and experiments using standout distances less than onemillimeter demonstrate recovery of at least fifty percent to at leastninety percent of the gas 160 used in a particular CSAM sessionincorporating the gas recovery nozzle 100 fitted with the flexiblecoupling 150, depending on the standout distance. These models andexperiments further indicate that implementations using a standoutdistance of 0.5 millimeters perform well, and the performance ofimplementations using 0.25 or less millimeters is optimal. FIG. 1illustrates the gas recovery nozzle 100 comprising the flexible coupling150 configured to mitigate the standout distance effect described above.By contrast, FIG. 5 as discussed elsewhere herein illustrates animplementation of a gas recovery nozzle not including the flexiblecoupling 150, demonstrating that implementations of the disclosure arestill functional even when a flexible coupling or gas capture cover isnot present to mitigate the standout distance effect.

Some implementations of the gas recovery nozzle 100 further comprise aheat transfer device 170 proximate to the supersonic nozzle 180 and themain body 102. The heat transfer device 170 is configured to regulate atemperature of the gas 160 such that the gas recovery nozzle 100 isprotected from heat-induced damage from a flow of the gas 160. In somesuch implementations, the heat transfer device 170 further comprises aliquid cooling system. The heat transfer device 170 is any suitabledevice for transferring waste heat. Depending on the requirements of aparticular application of an implementation of the gas recovery nozzle100, the heat transfer device 170 is at least one of a heat pipe, heatsink, liquid cooling tube, or any other suitable heat transfer device ormechanism that is capable of transferring waste heat away from the gas160 and or the gas recovery nozzle 100. The gas expansion will reducethe temperature of the gas proximate to the first end 104, cooling ismore relevant close to the second end 114.

In some implementations, the heat transfer device 170 is an open system,such as a liquid cooling tube wherein the fluid flowing through theliquid cooling tube is in thermal communication with one or moreadditional heat transfer devices, such as a heat sink such that heat maybe transferred from the heat transfer device 170 to the heat sink. Forinstance, the heat sink can be cooled with air, liquid, or a fan, or theheat sink can be a cold plate, or any other suitable heat sink. In someother implementations, waste heat carried by the heat transfer device170 is dissipated into space using protrusions in thermal communicationwith the heat transfer device 170.

In some other implementations, the heat transfer device 170 is a closedsystem (e.g., a pulsating heat pipe (“PHP”) or loop heat pipe (“LHP”)).Each of the PHP and LHP are passive devices that operate under pressuredifferences caused by heat to force heated fluid to propagate toward aheat sink or other location where waste heat is withdrawn from thefluid. In yet other implementations, the heat transfer device 170utilizes various configurations of heat pipes, such as straight, curved,crossing, or any number of configurations for achieving a desired amountof cooling. The heat transfer device 170 is configuration in variousimplementations to surround at least a portion of the main body 102 andbe positioned between the main body 102 and the supersonic nozzle 180.

FIG. 2 is a side elevation illustration of a spray path of animplementation of a cold spray additive manufacturing system 200 in usein accordance with an implementation. The cold spray additivemanufacturing system 200 does not show a gas recovery nozzle (e.g., thegas recovery nozzle 100 of FIG. 1 ), but instead illustrates how gas 208(e.g., the gas 160 of FIG. 1 ) is lost when the gas recovery nozzle isnot present. A nozzle 202 (e.g., the supersonic nozzle 180 of FIG. 1 )propels additive particles 204 along the additive vector 210 to asubstrate 206 through the nozzle 202 at a supersonic speed using the gas208 to perform cold spray additive manufacturing of a part 212. Whilethe additive particles 204 bond to the part 212 as described in FIG. 5herein, the used gas escapes laterally along the substrate of the part212, on the escape vector 220. Without use of the gas recovery nozzle asdisclosed elsewhere herein, all of the gas 208 is lost along the escapevector 220 and cannot be reused. In some implementations, there aremultiple escape vectors 220, each with a different direction. Gastraversing along any of the escape vectors 220 is permanently lost.

FIG. 3 is a flowchart illustrating a method 300 for performing coldspray additive manufacturing of a part (e.g., the part 152) inaccordance with an implementation. In some implementations, the processshown in FIG. 3 is performed by, at least in part, a gas recoverynozzle, a supersonic nozzle, a heat transfer device, and a gas recoverysub-system, such as the gas recovery nozzle 100, the supersonic nozzle180, the heat transfer device 170, and the gas recovery sub-system 190in FIG. 1 . The method 300 propels particles to a substrate through anozzle at a supersonic speed using a gas to perform cold spray additivemanufacturing of a part at operation 302, captures a flow of the gaspropelled from an end of the nozzle at operation 304, and circulates theflow of the gas to a gas recovery system at operation 306. The method300 allows for in-situ cold spray additive manufacturing of a part. Insome implementations, the substrate comprises at least one of theoriginal substrate of a part or material (e.g., particles) appliedpreviously to the original substrate (e.g., via a previous applicationof a CSAM method).

Thereafter, the process is complete. While the operations illustrated inFIG. 3 are performed by, at least in part, a gas recovery nozzle, asupersonic nozzle, a heat transfer device, and a gas recoverysub-system, aspects of the disclosure contemplate performance of theoperations by other entities. In some implementations, a cloud serviceperforms one or more of the operations (e.g., by controlling the nozzleto cause particles to be propelled to a substrate through a nozzle at asupersonic speed using a gas to perform cold spray additivemanufacturing of a part). In some implementations of the method 300, thepropelling of particles comprises structurally repairing the part insitu as further described elsewhere in this disclosure. In some otherimplementations, the gas comprises an at least one of a high-pressureHelium or Nitrogen gas. In yet other implementations, the gas comprisesan at least one of a low-pressure Helium or Nitrogen gas.

FIG. 4 is a flow chart illustrating another method 400 for performingcold spray additive manufacturing of a part (e.g., the part 152) inaccordance with an implementation. In some implementations, the methodshown in FIG. 4 is performed by, at least in part, a gas recoverynozzle, a supersonic nozzle, a heat transfer device, a gas recoverysub-system, a flexible coupling, and a gas capture cover, such as thegas recovery nozzle 100, the supersonic nozzle 180, the heat transferdevice 170, the gas recovery sub-system 190, the flexible coupling 150,and the gas capture cover 154 in FIG. 1 . The method 400 uses a flexiblecoupling attached to an end of the nozzle to seal a gas capture cover,coupled to the nozzle, to the part at operation 402. Operations 404,406, and 408 are similar to operations 302, 304, and 306 of the method300 depicted in FIG. 3 , and accordingly the description will not berepeated. The method 400 accommodates for variations in standoutdistances as described in more detail herein.

Thereafter, the process is complete. While the operations illustrated inFIG. 4 are performed by performed by, at least in part, a gas recoverynozzle, a supersonic nozzle, a heat transfer device, a gas recoverysub-system, a flexible coupling, and a gas capture cover, aspects of thedisclosure contemplate performance of the operations by other entities.In some implementations, a cloud service performs one or more of theoperations (e.g., by controlling the nozzle to cause particles to bepropelled to a substrate through a nozzle at a supersonic speed using agas to perform cold spray additive manufacturing of a part).

An operating environment is illustrated in FIG. 5 showing a blockdiagram of an implementation of a system 500 for performing cold sprayadditive manufacturing with gas recovery in accordance with animplementation. The system 500 comprises a robotic control system 502configured to control a cold spray apparatus 504. In someimplementations, the robotic control system further comprises a roboticpositioning arm 516 (e.g., robotically controlled mechanical arm). Insome implementations, the robotic control system 502 is a manual or atleast partially automated apparatus. In some such implementations, therobotic control system is controllable using a computing device, such asthe computing device 800 of FIG. 8 herein. In some implementations, therobotic positioning arm 516 is at least a five-axis positioning systemthat includes two axes for positioning in a plane of the part underrepair, one axis for the standout distance, and two additional axes foradditional requisite positioning. Alternatively, the robotic positioningarm 516 is at least a two axis positioning system for XY positioning inthe plane of part under repair and a rolling system that maintainsparallelism and standout distance with the substrate of the part underrepair. The robotic positioning arm 516, in some implementations, is anADEPT® Viper robot from Omron Adept Technologies, Inc.

The cold spray apparatus 504 of the system 500 further comprises asupersonic nozzle 535 (e.g., implemented as the supersonic nozzle 180 ofFIG. 1 ) and is configured to perform cold spray additive manufacturingof a part 506 (e.g., the part 152 of FIG. 1 ). In some implementations,the cold spray apparatus 504 is further configured to cold spray apowder 530 onto a substrate 551 of the part 506. In suchimplementations, the cold spray apparatus 504 further comprises a source518 of gas 512 connected to a gas control module 520. The gas controlmodule 520 controls the flow of the gas 512 through a first line 515connected to the supersonic nozzle 535 and through a second line 520connected to a powder chamber 531 and then to the supersonic nozzle 535.The cold spray apparatus 504 additionally comprises a heater 525 thatheats the gas 512 to a requisite temperature prior to entrance of thegas 512 into the supersonic nozzle 535. In some implementations, thesubstrate 551 is also heated to further facilitate mechanical bonding.

In operation, the gas 512 flows through the first line 515 and thesecond line 520 causing the powder 530 located within the powder chamber531 to be sprayed in a supersonic gas jet from the supersonic nozzle 535as a particle stream 540. The particle stream 540 is sprayed at atemperature below the melting point of the powder 530 and travels at asupersonic velocity from the supersonic nozzle 535. In someimplementations, the particle stream 540 travels at several times thespeed of sound. (The exact speed of sound at a given time variesdepending on local conditions). In some implementations, the particlestream 540 travels at least two- to four-times the speed of sound. Theparticle stream is deposited on the substrate 551 of the part 506,whereby on impact on the substrate 551, particles of the particle stream540 undergo plastic deformation due to the supersonic velocity of theparticle stream 540 and bond to each other and the substrate 551 of thepart 506 using mechanical energy. The heater 525 accelerates the speedof the particle stream 540, but the heat from the heated gas 512 is nottransferred to the bonding of the particles of the particle stream 540.Thus, the heat cannot cause deformities, warping, stresses, or otherdeleterious impacts to the bonding. In some implementations, once thecold spray process is complete the substrate 551 is further processes,such as polished to create or restore a smooth finish.

The system 500 further comprises a gas recovery nozzle 508 (e.g.,implemented as the gas recovery nozzle 100 of FIG. 1 ). The gas recoverynozzle 508 comprises a main body (e.g., implemented as the main body 102of FIG. 1 ) configured to attach to the supersonic nozzle; a first end(e.g., implemented as the first end 104 of FIG. 1 ) having angled walls(e.g., implemented as the angled walls 106 of FIG. 1 ) at an opening(e.g., implemented as the opening 108 of FIG. 1 ) defining a gas flowpath (e.g., implemented as the gas flow path 110 of FIG. 1 ) from thesupersonic nozzle and a passage (e.g., implemented as the passage 112 ofFIG. 1 ) extending from the first end to a second end (e.g., implementedas the second end 114 of FIG. 1 ), the first end being a distal end andthe second end being a proximal end relative to the supersonic nozzle.

The gas recovery nozzle 508 further comprises a cavity (e.g.,implemented as the cavity 116 of FIG. 1 ) surrounding the passage andconfigured to collect at least some gas 512 (e.g., such as the gas 160of FIG. 1 ) expelled from the supersonic nozzle and defining a gasrecovery path (e.g., implemented as the gas recovery path 162 of FIG. 1), and an outlet (e.g., implemented as the outlet 118 of FIG. 1 ) withinthe main body configured to connect to a gas recovery sub-system 510(e.g., implemented the gas recovery sub-system 190 of FIG. 1 ). The gasrecovery sub-system 510 is configured to connect to the outlet and alsoconfigured to collect at least some gas 512 expelled from the supersonicnozzle 535 through the gas recovery path into a storage device 514(e.g., implemented as the moveable gas recovery tank 194 of FIG. 1 ).The gas 512 is thereby collected into the storage device 514 and isstored for treatment and reuse in the cold spray apparatus 504.

In some implementations, the gas recovery sub-system 510 furthercomprises a gas condenser 560 configured to condense at least some gas512 in the storage device 514, such that storage device 514 stores thegreatest possible volume of at least some gas 512. In someimplementations, the gas condenser 560 is the compressor pump 192 ofFIG. 1 or an equivalent device. The storage device 514 is configured tobe transportable to a purifier configured to remove all contaminantsfrom at least some gas 512 such that at least some gas 512 is suitablefor re-use in the cold spray apparatus 504.

ADDITIONAL EXAMPLES

In general, there are two types of cold spray repair techniques.Non-Structural Cold Spray is concerned with adding thickness to a part.This technology has been developed and matured to the point that theUnited States Department of Defense has installed Non-Structural ColdSpray repair systems at many depots. Non-structural cold spray does notrequire the use of Helium carrier gas, due to less demanding mechanicalrequirements. Various implementations of the disclosure herein aretargeted to Structural Cold Spray, which is concerned not merely withadding thickness to existing parts but reconditioning and repair ofdamaged, worn, or otherwise out of spec parts. Among other applications,Structural Cold Spray is suitable to repair corrosion, repair cracks, orrestore tolerances/exact dimensions. Additionally, some implementationsof Structural Cold Spray do not require stripping and reapply the finishof the part subject to repair. As disclosed herein, CSAM mechanicallybonds particles to a substrate using purely mechanical energy, with noneed for added adhesives.

The implementations herein provide apparatuses, methods, and systems forusing cold spray technology to conduct structural repairs in situ bycapturing the flow of gas from the supersonic nozzle during a cold sprayprocess and circulating the gas to a gas recovery sub-system for laterreuse in additional cold spray processes. Some implementations of thegas recovery nozzle incorporate a cover (e.g., a flexible coupling) tocapture the flow of gas and circulate the gas to the gas recoverysub-system. The disclosure herein operates at the point of repair tocapture spent gas proximate to a supersonic nozzle via a gas recoverynozzle and store the gas for later purification and reuse.

Unless otherwise stated, any implementation described herein as beingincorporated into or being used in combination with a specific type ofvehicle (e.g., an aircraft or helicopter) shall be understood to beinstallable into and usable with any other type of vehicle (e.g.,trains, submersibles, tanks, armored personnel carriers, watercraft,etc.). Implementations of the disclosure herein are well-suited torepairing aircraft in-situ as described elsewhere herein, allowing theservice life of such aircraft to be maximally extended at lesser cost.Cold spray is recognized by various organizations as a solution distinctfrom and advantageous over thermal spray.

In particular, as aircraft enter the extreme ends of repeatedly extendedservice lifetimes, inevitably fleet fatigue causes cracks and otherdamage requiring structural repairs, part replacement, and part repairto keep the aircraft in service. This escalates the cost of keeping suchaircraft flying due to requiring recurrent inspections to maintain airworthiness, eventual retrofits, and long lead times and high expensesassociated with supply chain issues. Cold spray is especially wellsuited to perform these types of repairs in situ to rehabilitateexisting parts of such aircraft (e.g., repairs performed on aircraftcomponents in an aircraft hangar without disassembly), potentiallysignificantly reducing maintenance costs and also lowing downtime formilitary aircraft platforms. In 2008 (with revisions following in 2011and 2015), the United States Department of Defense adopted andpromulgated MIL Spec MIL-STD-3021 (“DOD Manufacturing Process Standard,Materials Deposition, Cold Spray”). The MIL-STD-3021 standard has beenadopted by various other organizations around the world.

The disclosure herein is usable in a number of present military andcommercial cold spray applications. Such applications include but arenot limited to:

-   -   Use by the United States Army through Maintenance Engineering        Order T-7631 by the Program Office UH-60 Blackhawk for the        repair of magnesium aerospace components;    -   Use in maintenance and repair of landing gear hydraulics for the        B1 Rockwell B-1 Lancer supersonic heavy bomber;    -   Research by the U.S. Army Research Laboratory in collaboration        with private industry for applications for additive        manufacturing as diverse as near-net forming of shape charge        liners, donor tubes for explosive cladding and sputter targets;    -   Automotive repairs;    -   Magnesium aerospace component repairs; and    -   A growing number of worldwide RDT and E programs other qualified        aerospace repair procedures worldwide.

At the time of this disclosure, in cold spray applications using Heliumwithout any means to recover and reuse the gas, the cost of each coldspray additive manufacturing repair session can include at least$1,000-$2,000 per hour in unrecoverable, single-use Helium expenditures.In many instances, this comprises the majority of the expense for suchcold spray additive manufacturing repair sessions. Such sessions takemore time and cost more money the more complex the part is that is underrepair. Without a means to reuse the Helium, the commercial economicviability of CSAM repair is severely curtailed.

Various implementations herein use a gas recovery sub-system (e.g., thegas recovery sub-system 190 of FIG. 1 or 510 of FIG. 5 ) to gather andstore used gas for later purification and reuse in future cold sprayadditive manufacturing processes. The disclosure is usable with a numberof commercially available purification/purifier systems, including thoseboth presently available and not yet released. In some implementations,the disclosure is usable with QUANTUMPURE CS™ and QuantumPure CS-TRIGAS™ Helium recovery and purification systems by Quantum TechnologyCorporation.

At least a portion of the functionality of the various elements in thefigures are in some implementations performed by other elements in thefigures, and or an entity (e.g., a computer) not shown in the figures.

In some implementations, the operations illustrated in FIG. 3 and FIG. 4are performed by a single person, a group of persons, a fully- orpartially-automated cold spray additive manufacturing with gas recoverysystem, or any combination of the foregoing. As an illustration, in someimplementations the gas recovery nozzle, supersonic nozzle, heattransfer device, and gas recovery sub-system are each be provided bydistinct suppliers to a wholly separate assembler who couples the gasrecovery nozzle to the supersonic nozzle.

While the aspects of the disclosure have been described in terms ofvarious implementations with their associated operations, a personskilled in the art would appreciate that a combination of operationsfrom any number of different implementations is also within scope of theaspects of the disclosure.

Exemplary Operating Environment

The present disclosure is operable within an aircraft manufacturing andservice method according to an implementation as a method 600 in FIG. 6. During pre-production of the aircraft, some implementations of method600 include specification and design of the aircraft at operation 602,and material procurement at operation 604. During production, someimplementations of method 600 include component and subassemblymanufacturing at operation 606 and aircraft system integration atoperation 608. The aircraft undergoes certification and delivery atoperation 610 in order to be placed in service at operation 612. Whilein service of a customer, the aircraft is scheduled for routinemaintenance and service at operation 614. In some implementations,operation 614 comprises modification, reconfiguration, refurbishment,and other operations associated with maintaining the aircraft inacceptable, safe condition during ongoing flight operations. Systems andmethods for cold spray additive manufacturing as disclosed herein areused during operation 614.

Each of the processes of method 600 are performable or practicable by asystem integrator, a third party, or an operator (e.g., a customer). Forthe purposes of this disclosure, a system integrator comprises anynumber of aircraft manufacturers and major-system subcontractors; athird party comprises any number of vendors, subcontractors, andsuppliers; and an operator comprises an airline, leasing company,military entity, service organization, and similar entities providingsimilar sales and leasing services.

The present disclosure is operable in a variety of terrestrial andextra-terrestrial environments for a variety of applications. Forillustrative purposes only, and with no intent to limit the possibleoperating environments in which implementations of the disclosureoperate, the following exemplary operating environment is presented. Thepresent disclosure is operable within an aircraft operating environmentaccording to an implementation as an aircraft 700 in FIG. 7 .Implementations of the aircraft 700 include but are not limited to anairframe 702, a plurality of high-level systems 704, and an interior706. Some implementations of the aircraft 700 incorporate high-levelsystems 704 including but not limited to: one or more of a propulsionsystem 708, an electrical system 710, a hydraulic system 712, and anenvironmental system 714. Any number of other systems may be included inimplementations of the aircraft 700. Although an aerospaceimplementation is shown, the principles are applicable to otherindustries, such as the automotive and nautical industries.

The present disclosure is operable with a computing apparatus accordingto an implementation as a functional block diagram 800 in FIG. 8 . Insuch an implementation, components of a computing apparatus 818 may beimplemented as a part of an electronic device according to one or moreimplementations described in this specification. The computing apparatus818 comprises one or more processors 819 which may be microprocessors,controllers or any other suitable type of processors for processingcomputer executable instructions to control the operation of theelectronic device. Platform software comprising an operating system 820or any other suitable platform software may be provided on the apparatus818 to enable application software 821 to be executed on the device.According to an implementation, the cold spray additive manufacturingsystem as described herein may be implemented at least partially bysoftware.

Computer executable instructions may be provided using anycomputer-readable media that are accessible by the computing apparatus818. Computer-readable media may include, without limitation, computerstorage media such as a memory 822 and communications media. Computerstorage media, such as a memory 822, include volatile and non-volatile,removable and non-removable media implemented in any method ortechnology for storage of information such as computer readableinstructions, data structures, program modules or the like. Computerstorage media include, but are not limited to, RAM, ROM, EPROM, EEPROM,flash memory or other memory technology, CD-ROM, digital versatile disks(DVD) or other optical storage, magnetic cassettes, magnetic tape,magnetic disk storage or other magnetic storage devices, or any othernon-transmission medium that is usable to store information for accessby a computing apparatus. In contrast, communication media may embodycomputer readable instructions, data structures, program modules, or thelike in a modulated data signal, such as a carrier wave, or othertransport mechanism. As defined herein, computer storage media do notinclude communication media. Therefore, a computer storage medium shouldnot be interpreted to be a propagating signal per se. Propagated signalsper se are not examples of computer storage media. Although the computerstorage medium (the memory 822) is shown within the computing apparatus818, it will be appreciated by a person skilled in the art, that thestorage may be distributed or located remotely and accessed via anetwork or other communication link (e.g., using a communicationinterface 823).

The computing apparatus 818 may comprise an input/output controller 824configured to output information to one or more output devices 825, insome implementations a display or a speaker, which may be separate fromor integral to the electronic device. The input/output controller 824may also be configured to receive and process an input from one or moreinput devices 826, in some implementations a keyboard, a microphone or atouchpad. In one implementation, the output device 825 may also act asthe input device. A touch sensitive display is one such device. Theinput/output controller 824 may also output data to devices other thanthe output device, e.g., a locally connected printing device. In someimplementations, a user may provide input to the input device(s) 826and/or receive output from the output device(s) 825.

The functionality described herein is performable, at least in part, byone or more hardware logic components. According to an implementation,the computing apparatus 818 is configured by the program code whenexecuted by the processor 819 to execute the implementations of theoperations and functionality described. Alternatively, or in addition,the functionality described herein is performable, at least in part, byone or more hardware logic components. Without limitation, illustrativetypes of hardware logic components that are usable includeField-programmable Gate Arrays (FPGAs), Application-specific IntegratedCircuits (ASICs), Program-specific Standard Products (ASSPs),System-on-a-chip systems (SOCs), Complex Programmable Logic Devices(CPLDs), Graphics Processing Units (GPUs).

Thus, various implementations include systems and methods for performingcold spray additive manufacturing with gas recovery comprisingpropelling particles to a substrate through a nozzle at a supersonicspeed using a gas to perform cold spray additive manufacturing of apart; capturing a flow of the gas propelled from an end of the nozzle;and circulating the flow of the gas to a gas recovery system.

As described herein, the present disclosure provides systems and methodsfor cold spray additive manufacturing with gas recovery. The systems andmethods herein efficiently and effectively construct and deploy withincold spray additive manufacturing with gas recovery system suitable foruse in connection with repairs in situ of a number of moving vehicles,including but not limited to the above exemplary operating environment.

While various spatial and directional terms, such as top, bottom, lower,mid, lateral, horizontal, vertical, front and the like may be used todescribe the present disclosure, it is understood that such terms aremerely used with respect to the orientations shown in the drawings. Theorientations may be inverted, rotated, or otherwise changed, such thatan upper portion is a lower portion, and vice versa, horizontal becomesvertical, and the like.

As used herein, a structure, limitation, or element that is “configuredto” perform a task or operation is particularly structurally formed,constructed, or adapted in a manner corresponding to the task oroperation. For purposes of clarity and the avoidance of doubt, an objectthat is merely capable of being modified to perform the task oroperation is not “configured to” perform the task or operation as usedherein.

Any range or value given herein is extendable or alterable withoutlosing the effect sought, as will be apparent to the skilled person.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexemplary forms of implementing the claims.

It will be understood that the benefits and advantages described abovecan relate to one implementation or can relate to severalimplementations. The implementations are not limited to those thataddress every issue discussed in the Background herein or those thathave any or all of the stated benefits and advantages.

The implementations illustrated and described herein as well asimplementations not specifically described herein but within the scopeof aspects of the claims constitute exemplary means for cold sprayadditive manufacturing with gas recovery.

The order of execution or performance of the operations inimplementations of the disclosure illustrated and described herein isnot essential, unless otherwise specified. That is, the operations maybe performed in any order, unless otherwise specified, and examples ofthe disclosure may include additional or fewer operations than thosedisclosed herein. As an illustration, it is contemplated that executingor performing a particular operation before, contemporaneously with, orafter another operation is within the scope of aspects of thedisclosure.

When introducing elements of aspects of the disclosure or theimplementations thereof, the articles “a,” “an,” “the,” and “said” areintended to mean that there are one or more of the elements. The terms“comprising,” “including,” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. The term “exemplary” is intended to mean “an example of” Thephrase “one or more of the following: A, B, and C” means “at least oneof A and/or at least one of B and/or at least one of C.”

Having described aspects of the disclosure in detail, it will beapparent that modifications and variations are possible withoutdeparting from the scope of aspects of the disclosure as defined in theappended claims. As various changes could be made in the aboveconstructions, products, and methods without departing from the scope ofaspects of the disclosure, it is intended that all matter contained inthe above description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

It is to be understood that the above description is intended to beillustrative, and not restrictive. As an illustration, theabove-described implementations (and/or aspects thereof) are usable incombination with each other. In addition, many modifications arepracticable to adapt a particular situation or material to the teachingsof the various implementations of the disclosure without departing fromtheir scope. While the dimensions and types of materials describedherein are intended to define the parameters of the variousimplementations of the disclosure, the implementations are by no meanslimiting and are exemplary implementations. Many other implementationswill be apparent to those of ordinary skill in the art upon reviewingthe above description. The scope of the various implementations of thedisclosure should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, the terms “first,” “second,”and “third,” etc. are used merely as labels, and are not intended toimpose numerical requirements on their objects. Further, the limitationsof the following claims are not written in means-plus-function formatand are not intended to be interpreted based on 35 U.S.C. § 112(f),unless and until such claim limitations expressly use the phrase “meansfor” followed by a statement of function void of further structure.

This written description uses examples to disclose the variousimplementations of the disclosure, including the best mode, and also toenable any person of ordinary skill in the art to practice the variousimplementations of the disclosure, including making and using anydevices or systems and performing any incorporated methods. Thepatentable scope of the various implementations of the disclosure isdefined by the claims, and includes other examples that occur to thosepersons of ordinary skill in the art. Such other examples are intendedto be within the scope of the claims if the examples have structuralelements that do not differ from the literal language of the claims, orif the examples include equivalent structural elements withinsubstantial differences from the literal language of the claims.

CLAUSES

The following clauses describe further aspects:

Clause Set A:

A1. A gas recovery nozzle comprising:

-   -   a main body configured to attach to a supersonic nozzle;    -   a first end having angled walls at an opening defining a gas        flow path from the supersonic nozzle;    -   a passage extending from the first end to a second end, the        first end being a distal end and the second end being a proximal        end relative to the supersonic nozzle;    -   a cavity surrounding the passage and configured to collect at        least some gas expelled from the supersonic nozzle and defining        a gas recovery path;    -   an outlet within the main body configured to connect to a gas        recovery sub-system.

A2. The gas recovery nozzle of any preceding clause, wherein the outletcomprises an opening configured to connect to a compressor pump of thegas recovery sub-system; and wherein the cavity further comprises a gasdiffuser;

-   -   the gas diffuser configured to slow the flow of the at least        some gas inside the cavity to the opening;    -   whereby the gas diffuser facilitates at least one of slowing the        flow of the at least some gas or directing the flow of the at        least some gas to the compressor pump.

A3. The gas recovery nozzle of any preceding clause, wherein the outletcomprises an opening configured to connect to a movable gas recoverytank.

A4. The gas recovery nozzle of any preceding clause, wherein the gascomprises an at least one of Helium or Nitrogen gas.

A5. The gas recovery nozzle of any preceding clause, wherein the mainbody is tubular and configured to surround an end of the supersonicnozzle.

A6. The gas recovery nozzle of any preceding clause, wherein the mainbody is configured as a removable cover to capture a flow of gas fromthe supersonic nozzle and circulate the gas to the gas recoverysub-system.

A7. The gas recovery nozzle of any preceding clause, wherein the mainbody is configured as a removable cover to suppress noise during a coldspray process wherein gas is expelled from the supersonic nozzle.

A8. The gas recovery nozzle of any preceding clause, wherein an open endof the cavity at a part side comprises curved walls.

A9. The gas recovery nozzle of any preceding clause, wherein the openend of the cavity extends farther distally than the opening at the firstend.

A10. The gas recovery nozzle of any preceding clause, further comprisinga flexible coupling attached to the first end and configured to engage apart.

Clause Set B:

B1. A method for performing cold spray additive manufacturing, themethod comprising:

-   -   propelling particles to a substrate through a nozzle at a        supersonic speed using a gas to perform cold spray additive        manufacturing of a part;    -   capturing a flow of the gas propelled from an end of the nozzle;        and    -   circulating the flow of the gas to a gas recovery system.

B2. The method of any preceding clause, wherein the propelling ofparticles comprises structurally repairing the part in situ.

B3. The method of any preceding clause, wherein the gas comprises an atleast one a of a high-pressure Helium or Nitrogen gas.

Clause Set C:

C1. A system for performing cold spray additive manufacturing with gasrecovery (500), comprising:

-   -   a robotic control system configured to control a cold spray        apparatus;    -   the cold spray apparatus having a supersonic nozzle, the cold        spray apparatus configured to perform cold spray additive        manufacturing of a part;    -   a gas recovery nozzle comprising:        -   a main body configured to attach to the supersonic nozzle;        -   a first end having angled walls at an opening defining a gas            flow path from the supersonic nozzle;        -   a passage extending from the first end to a second end, the            first end being a distal end and the second end being a            proximal end relative to the supersonic nozzle;        -   a cavity surrounding the passage and configured to collect            at least some gas expelled from the supersonic nozzle and            defining a gas recovery path;        -   an outlet within the main body configured to connect to a            gas recovery sub-system; and    -   the gas recovery sub-system configured to connect to the outlet        and also configured to collect at least some gas expelled from        the supersonic nozzle through the gas recovery path into a        storage device;    -   whereby at least some gas collected into the storage device is        stored for treatment and reuse in the cold spray apparatus.

C2. The system of any preceding clause, wherein the robotic controlsystem further comprises a robotic positioning arm.

C3. The system of any preceding clause, wherein the cold spray apparatusis further configured to cold spray a powder onto a substrate of a part,the cold spray apparatus further comprising:

-   -   a source of gas connected to a gas control module, the gas        control module controlling the flow of the gas through a first        line connected to the supersonic nozzle and through a second        line connected to a powder chamber and then to the supersonic        nozzle;    -   a heater that heats the gas to a requisite temperature prior to        entrance of the gas into the supersonic nozzle;    -   the gas flowing through the first line and the second line        causing the powder located within the powder chamber to be        sprayed in a supersonic gas jet from the supersonic nozzle as a        particle stream, the particle stream being sprayed at a        temperature below the melting point of the powder;    -   the particle stream travelling at a supersonic velocity from the        supersonic nozzle and being deposited on the substrate of the        part;    -   whereby on impact on the substrate, particles of the particle        stream undergo plastic deformation due to the supersonic        velocity of the particle stream and bond to each other; and    -   whereby the heater accelerates the speed of the particle stream,        but the heat from the heated gas is not transferred to the        bonding of the particles of the particle stream.

C4. The system of any preceding clause, wherein the gas recoverysub-system further comprises:

-   -   a gas condenser configured to condense the at least some gas in        the storage device, such that storage device stores the greatest        possible volume of at least some gas;    -   the storage device configured to be transportable to a purifier;    -   the purifier being configured to remove all contaminants from        the at least some gas such that the at least some gas is        suitable for re-use in the cold spray apparatus.

What is claimed is:
 1. A gas recovery nozzle comprising: a main bodyconfigured to attach to a supersonic nozzle and a first pressure supply;a first end having an angled wall that expands outwardly from an openingdefining a gas flow path from the supersonic nozzle; a passage extendingfrom the first end to a second end, the first end being a distal end andthe second end being a proximal end relative to the supersonic nozzle; acavity surrounding the passage and configured to collect at least somegas expelled from the supersonic nozzle and defining a gas recoverypath, wherein an open end of the cavity is located at a part side of themain body and comprises a curved wall that tapers adjacent the part sideand expands adjacent an interior of the cavity; and an outlet within thecavity configured to connect to a gas recovery sub-system, and a secondpressure supply of the gas recovery sub-system.
 2. The gas recoverynozzle of claim 1, wherein the second pressure supply is a compressorpump of the gas recovery sub-system; and wherein the cavity furthercomprises a gas diffuser; the gas diffuser is configured to slow theflow of the at least some gas inside the cavity to the opening; wherebythe gas diffuser facilitates at least one of slowing the flow of the atleast some gas or directing the flow of the at least some gas to thecompressor pump.
 3. The gas recovery nozzle of claim 1, wherein theoutlet comprises an opening configured to connect to a movable gasrecovery tank.
 4. The gas recovery nozzle of claim 1, wherein the gascomprises an at least one of Helium or Nitrogen gas.
 5. The gas recoverynozzle of claim 1, wherein the main body is tubular and configured tosurround an end of the supersonic nozzle.
 6. The gas recovery nozzle ofclaim 1, wherein the main body is configured as a removable cover tocapture a flow of gas from the supersonic nozzle and circulate the gasto the gas recovery sub-system.
 7. The gas recovery nozzle of claim 1,wherein the main body is configured as a removable cover to suppressnoise during a cold spray process wherein gas is expelled from thesupersonic nozzle.
 8. The gas recovery nozzle of claim 1, wherein theopen end of the cavity extends farther distally than the opening at thefirst end.
 9. The gas recovery nozzle of claim 1, further comprising aflexible coupling attached to the first end and configured to engage apart.
 10. The gas recovery nozzle of claim 1, further comprising a heattransfer device proximate to the supersonic nozzle and the main body,the heat transfer device configured to regulate a temperature of the gassuch that the recovery nozzle is protected from heat-induced damage froma flow of the gas.
 11. The gas recovery nozzle of claim 10, wherein theheat transfer device further comprises a liquid cooling system.
 12. Asystem for performing cold spray additive manufacturing with gasrecovery, comprising: a robotic control system configured to control acold spray apparatus; the cold spray apparatus having a supersonicnozzle, the cold spray apparatus configured to perform cold sprayadditive manufacturing of a part; a gas recovery nozzle comprising: amain body configured to attach to the supersonic nozzle and a firstpressure supply; a first end having an angled wall that expandsoutwardly from an opening defining a gas flow path from the supersonicnozzle; a passage extending from the first end to a second end, thefirst end being a distal end and the second end being a proximal endrelative to the supersonic nozzle; a cavity surrounding the passage andconfigured to collect at least some gas expelled from the supersonicnozzle and defining a gas recovery path, wherein an open end of thecavity is located at a part side of the main body and comprises a curvedwall that tapers adjacent the part side and expands adjacent an interiorof the cavity; an outlet within the cavity configured to connect to agas recovery sub-system, and a second pressure supply of the gasrecovery sub-system; and the gas recovery sub-system configured toconnect to the outlet and also configured to collect the at least somegas expelled from the supersonic nozzle through the gas recovery pathinto a storage device; whereby the at least some gas collected into thestorage device is stored for treatment and reuse in the cold sprayapparatus.
 13. The system of claim 12, wherein the robotic controlsystem further comprises a robotic positioning arm.
 14. The system ofclaim 12, wherein the cold spray apparatus is further configured to coldspray a powder onto a substrate of a part, the cold spray apparatusfurther comprising: a source of gas connected to a gas control module,the gas control module controlling the flow of the gas through a firstline connected to the supersonic nozzle and through a second lineconnected to a powder chamber and then to the supersonic nozzle; aheater that heats the gas to a requisite temperature prior to entranceof the gas into the supersonic nozzle; the gas flowing through the firstline and the second line causing the powder located within the powderchamber to be sprayed in a supersonic gas jet from the supersonic nozzleas a particle stream, the particle stream being sprayed at a temperaturebelow the melting point of the powder; the particle stream travelling ata supersonic velocity from the supersonic nozzle and being deposited onthe substrate of the part; whereby on impact on the substrate, particlesof the particle stream undergo plastic deformation due to the supersonicvelocity of the particle stream and bond to each other; and whereby theheater accelerates the speed of the particle stream, but the heat fromthe heated gas is not transferred to the bonding of the particles of theparticle stream.
 15. The system of claim 12, wherein the gas recoverysub-system further comprises: a gas condenser configured to condense theat least some gas in the storage device, such that storage device storesthe greatest possible volume of the at least some gas; the storagedevice configured to be transportable to a purifier; the purifier beingconfigured to remove all contaminants from the at least some gas suchthat the at least some gas is suitable for re-use in the cold sprayapparatus.